JP4228962B2 - Connection terminal connection method and connection part - Google Patents

Description

  The present invention relates to a connection method for connection terminals connected to conductors of cable terminals.

  A connecting portion 70 shown in FIG. 7 is obtained by connecting the connection terminal 61 shown in FIG. 6 to the conductor of the cable terminal.

  Connection (fixation) between the connection terminal 61 and the conductor 71 of the cable terminal is performed by inserting the conductor 71 into the space 64 between the claw portions 62a and 62b of the connection terminal 61 and the flat portion 63, and then connecting the claw portions 62a and 62b. This is done by bending (inward) so as to be close to each other and fastening the conductor 71 with the claw portions 62a and 62b and the flat portion 63.

  As a constituent material of a conventional connection terminal, a Cu alloy mainly composed of Cu, such as brass, phosphor bronze, or white, is used in addition to pure copper. Further, in order to improve the connection between the connection terminal and the conductor, the surface of the connection terminal is subjected to Sn plating, Ni plating, or the like (for example, see Patent Document 1).

  In recent years, recycling of materials has become a problem due to environmental problems. Among them, steel materials are widely used as metal structural materials, and thus recycling is important.

  When recycling steel materials, specific metal materials such as Cu contained in iron scrap are problematic. This is because if the metal scrap contains a specific metal material such as Cu, Sn, Ni, or Cr, surface cracks and scratches are generated in the reclaimed steel material, resulting in quality degradation. These specific metal materials are very difficult to remove from the molten steel. For this reason, by repeating the recycling of the steel material, the concentration of the specific metal material is concentrated, and the quality of the steel material is further deteriorated. Therefore, it is desirable that the iron scrap is free of a specific metal material.

  Various wiring materials are used in automobiles, home appliances, and the like that constitute iron scrap. Here, if the members that make up these wiring materials are made of materials that are free of specific metal materials, there is no need to select wiring materials when recycling materials for automobiles, home appliances, etc., improving recyclability To do. Therefore, Al or an Al alloy has begun to be used as a constituent material of the connection terminal instead of the Cu alloy.

JP-A-11-135226

  However, since Al or Al alloy is more likely to undergo creep deformation than Cu alloy, slack is likely to occur in the tightening of the conductor by the connection terminal. As a result, the contact resistance between the conductor and the connection terminal increases, and heat is generated due to Joule heat. Since creep deformation is more likely to occur at higher temperatures, this heat generation further loosens the conductors by the connection terminals and increases the contact resistance, which further increases the temperature of the connection portion. There is a possibility that the connection between the conductor and the connection terminal may be disconnected due to repeated occurrence of slack and heat generation due to creep deformation.

  Further, the claw portions 62a and 62b and the flat portion 63 in the connection portion 70 and the conductor 71 are only physically in contact with each other by tightening, and this also causes a disconnection between the conductor and the connection terminal. It was.

An object of the present invention created in view of the above circumstances is to provide a connection method and a connection portion which are made of a material free of a specific metal material and have a strong connection with a conductor of a cable terminal.

Connection method for connecting terminal according to the present invention for achieving the above, in the method for connecting a connection terminal having a claw portion for folding clamping a conductor comprised of Al or an Al alloy of the cable terminal, a layer of Al alloy And the Fe alloy layer are laminated and clad, and the conductor is brought into contact with a connection terminal formed by placing the Al alloy layer at the contact portion with the conductor, and the claw portion is bent. Before applying vibration by ultrasonic waves to at least one of the conductor or the connection terminal, at least a part of the contact portion between the conductor and the Al alloy layer is melted and fused by frictional heat due to sliding friction. One fusion step, bending the claw portion of the connection terminal and tightening the conductor, passing a current between the conductor and the connection terminal, and in the contact portion between the conductor and the Al alloy layer, At least one And a second fusing step of fusing and fusing the portion with Joule heat due to electric resistance .

Here, the composite material has a conductivity of 28 × 10 ⁶ S / m or more and a tensile strength of 300 MPa or more.

  On the other hand, the connection part which concerns on this invention connects a conductor and a connection terminal using the connection method of the connection terminal mentioned above.

  According to the present invention, although it is a connection part using the connection terminal comprised with Al alloy, the outstanding effect that thermal shock resistance is good is exhibited.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of the invention will be described with reference to the accompanying drawings.

  As shown in FIG. 2, a connection terminal 21 according to a preferred embodiment of the present invention is connected to a conductor of a cable terminal, and is an Al alloy layer 11 mainly composed of Al shown in FIG. And a composite material 10 formed by laminating and cladding two or more layers (only two layers are shown in FIG. 1) of Fe (or Fe and Al) as a main component, and a conductor. The Al alloy layer 11 is disposed on the contact portion (flat portion) 23 side (the upper surface side in FIG. 2).

  The connection terminal 21 is formed by bending the claw portions 22a and 22b of the T-shaped main body portion 25 so as to be substantially orthogonal to the upper surface F of the main body portion 25, and a flat portion 23 between the claw portions 22a and 22b on the upper surface F; A conductor is inserted and disposed in the space 24 between the claw portions 22a and 22b.

The composite 10 adjusts the thickness ratio (layer thickness ratio) of the layer 11 and the layer 12 to 3: 1 to 7: 1, preferably 4: 1 to 6: 1, particularly preferably around 5: 1. The conductivity is 28 × 10 ⁶ S / m or more, and the tensile strength is 300 MPa or more. The composite terminal 10 is appropriately subjected to a rolling process, a punching process, a bending process, and the like, whereby the connection terminal 21 is obtained.

  The layer 12 in the composite material 10 may be composed of a single layer material of Fe alloy, or may be composed of a clad material of Fe alloy material and Al alloy material.

  The Fe alloy may contain a specific metal material such as Cu, Sn, Ni, or Cr as an inevitable impurity, specifically in a range of less than 0.01% by weight.

Al alloy is
0.01-0.5 wt% Zr,
And less than 0.01% by weight of inevitable impurities.

Al alloy is
0.5-5.0 wt% Mg,
0.01-0.5 wt% Zr,
And less than 0.02% by weight of inevitable impurities.

Furthermore, Al alloy
0.5-5.0 wt% Mg,
0.1-1.0 wt% Si,
0.01-0.5 wt% Zr,
And less than 0.02% by weight of inevitable impurities.

Al alloy is
0.3-1.0 wt% Fe,
0.02 to 0.1% by weight of Zr,
And less than 0.02% by weight of inevitable impurities.

Furthermore, Al alloy
It may contain a specific metal material such as Cu, Sn, Ni, Cr or the like less than 0.01% by weight.

  The shape of the connection terminal 21 is not particularly limited, and any conventional connection terminal connected to the conductor of the cable end can be applied.

  Next, a connection terminal connection method according to the present embodiment will be described.

  After the conductor of the cable end (for example, a conductor made of Al or Al alloy) is inserted into the space 24 of the connection terminal 21 shown in FIG. 2, the ultrasonic transducer 35 is placed on the conductor 31 as shown in FIG. Further, the ultrasonic transducer 36 is brought into contact with the lower surface of the flat portion 23 of the connection terminal 21.

  Next, ultrasonic vibration is applied to each conductor 31 and connection terminal 21 by the ultrasonic vibrators 35 and 36, and the conductor 31 and the layer 11 in the connection terminal 21 are slid at high speed. This sliding frictional heat partially melts the conductor 31 and the layer 11 and the surfaces of the conductors 31. As a result, at least a part of the conductor 31 and the layer 11 and at least a part of the conductors 31 are fused and integrated to form the fused part 38. Here, at the time of applying ultrasonic vibrations by the ultrasonic vibrators 35 and 36, at least one of the ultrasonic vibrators 35 and 36 is moved in a direction close to each other, and the conductor 31 and the flat between the ultrasonic vibrators 35 and 36 are flat. The unit 23 may be compressed.

  Finally, the claw portions 22a and 22b of the connection terminal 21 are folded and abutted so as to be close to each other (inward), and the conductor 31 is fastened by the claw portions 22a and 22b and the flat portion 23, whereby the conductor 31 and the connection terminal 21 are connected. Is completed (fixed), and a connecting portion (cable) 30 is obtained.

  In addition, as the conductor made of Al or Al alloy, all those conventionally used as an aluminum conductor can be applied and are not particularly limited.

  Next, the operation of the present embodiment will be described.

The connection terminal 21 according to the present embodiment is composed of a composite material 10 in which an Al alloy layer 11 and an Fe alloy layer 12 are laminated in two or more layers and clad. In this composite material 10, the compositions and thicknesses of the layers 11 and 12 are adjusted so that the electrical conductivity is 28 × 10 ⁶ S / m or more and the tensile strength is 300 MPa or more. In other words, the composite material 10 is composed of a layer 11 (Al alloy) with good conductivity but insufficient strength and a layer (Fe alloy) 12 with sufficiently high strength but poor conductivity (Fe alloy) 12. Thus, the defects of the layers 11 and 12 are complemented with each other. As a result, the connection terminal 21 according to the present embodiment has a tensile force without greatly reducing the electrical conductivity as compared with a connection terminal made of conventional Al or Al alloy, for example, a connection terminal made of industrial pure aluminum. The strength can be greatly improved, for example, three times or more.

  In addition, the connection terminal 21 according to the present embodiment arranges the layer 11 so that the layer 11 made of an Al alloy is in contact with and connected to the conductor 31, and the conductivity between the connection terminal 21 and the conductor 31 is good. It is trying to become. For this reason, in the connection terminal 21, the favorable electrical conductivity of the conductor 31 comprised with Al or Al alloy does not have a possibility of impairing.

  Furthermore, the connection terminal 21 according to the present embodiment has high tensile strength and heat resistance because the layer 11 is reinforced by the layer 12 made of an Fe alloy.

  Further, the connection terminal 21 according to the present embodiment is made of a specific metal material-free material such as Cu, Sn, Ni, or Cr, or a material having a very small content of the specific metal material. For this reason, when disposing of automobiles and home appliances including a wiring material provided with a connection portion 30 (see FIG. 3) connecting the connection terminal 21 and the conductor 31, it is necessary to select the wiring material. Absent. Therefore, the recyclability of the steel material is improved.

  Furthermore, although a part of the connection terminal 21 according to the present embodiment is made of an Fe alloy, most of the connection terminal 21 is made of Cu or an Al alloy that is lighter than the Cu alloy. Therefore, the wiring material provided with the connection part 30 formed by connecting the connection terminal 21 and the conductor 31 made of Al or Al alloy is very lightweight, and is suitable for a high-level wiring part or an outdoor wiring part. It becomes.

  On the other hand, in the connection method of the connection terminal 21 according to the present embodiment, when the conductor 31 and the connection terminal 21 are connected, by applying ultrasonic vibration, at least a part of the conductor 31 and the layer 11, and the conductor At least a part of 31 is fused and integrated. For this reason, the connection strength between the conductor 31 and the connection terminal 21 of the connection portion 30 obtained by the connection method according to the present embodiment is the same as that of the conventional method in which the conductor 71 and the connection terminal 61 are physically brought into contact with each other. Compared to the connection strength of the connection portion 70 (see FIG. 7), the connection strength is very high. That is, the connection unit 30 has high connection reliability.

  For this reason, even if creep deformation occurs in the connection terminal 21 and the conductor 31 in the connection portion 30, there is almost no loosening in the tightening of the conductor 31 by the connection terminal 21. Therefore, the contact resistance between the conductor 31 and the connection terminal 21 does not increase, the connection portion 30 generates heat due to Joule heat due to the contact resistance, and the connection portion 30 does not reach a higher temperature. That is, since the slack and heat generation due to creep deformation do not repeatedly occur in a chain, the connection between the conductor 31 and the connection terminal 21 is not eventually lost.

  Moreover, even if the thermal cycle of holding for a certain period of time in the low temperature state and the high temperature state is repeatedly applied to the connection portion 30 according to the present embodiment, the resistivity of the connection portion 30 hardly changes. Therefore, the connection part 30 has very good thermal shock resistance.

  Furthermore, the connection part 30 according to the present embodiment can be applied to, for example, a connection part of a wire harness such as an automobile or a home appliance, and by applying to these, a highly reliable wire harness can be obtained. .

  Next, another embodiment of the present invention will be described with reference to the accompanying drawings.

  A joining method according to another preferred embodiment of the present invention will be described.

  After the conductor of the cable terminal is inserted and arranged in the space 24 of the connection terminal 21 shown in FIG. 2, the claws 22a and 22b of the connection terminal 21 are brought close to each other (inward) as shown in FIG. The conductor 31 is clamped by the claw portions 22a and 22b and the flat portion 23 by bending and butting.

  Next, the electrode 45 is brought into contact with the butted portion 42 in the claw portions 22 a and 22 b and the vicinity thereof, and the electrode 46 is brought into contact with the lower surface of the flat portion 23 of the connection terminal 21.

  Next, by applying a voltage between the electrodes 45, 46, the electrode 45 → the butted portion 42 of the connection terminal 21 → the conductor 31 → the flat portion 23 of the connection terminal 21 → the electrode 46 (in reverse order). Current flows. When this current flows, the conductor 31 and the layer 11 and the surfaces of the conductors 31 are partially thermally melted by the heat generated by the electrical resistance (Joule heat). As a result, at least a part of the conductor 31 and the layer 11 and at least a part of the conductors 31 are fused and integrated to form the fused part 38. Here, when a voltage is applied by the electrodes 45 and 46, at least one of the electrodes 45 and 46 is moved in a direction close to each other, and the abutting portion 42, the conductor 31, and the flat portion 23 between the electrodes 45 and 46 are compressed. You may do it.

  Thus, the connection (fixation) between the conductor 31 and the connection terminal 21 is completed, and the connection portion 40 is obtained.

  Also in the connection part 40 obtained using the connection method according to the present embodiment, the same effect as the connection part 30 obtained using the connection method according to the previous embodiment is expected.

  Moreover, the joining method which concerns on another suitable one Embodiment of this invention is demonstrated using FIGS.

  After the conductor of the cable terminal is inserted and arranged in the space 24 of the connection terminal 21 shown in FIG. 2, as shown in FIG. 3, the ultrasonic transducer 35 is placed on the conductor 31, and the flat portion 23 of the connection terminal 21 is placed. The ultrasonic transducer 36 is brought into contact with the lower surface.

  Next, ultrasonic vibration is applied to each conductor 31 and connection terminal 21 by the ultrasonic vibrators 35 and 36, and the conductor 31 and the layer 11 in the connection terminal 21 are slid at high speed. This sliding frictional heat partially melts the conductor 31 and the layer 11 and the surfaces of the conductors 31. As a result, at least a part of the conductor 31 and the layer 11 and at least a part of the conductors 31 are fused and integrated to form the fused part 38 (first fusion process). Here, at the time of applying ultrasonic vibrations by the ultrasonic vibrators 35 and 36, at least one of the ultrasonic vibrators 35 and 36 is moved in a direction close to each other, and the conductor 31 and the flat between the ultrasonic vibrators 35 and 36 are flat. The unit 23 may be compressed.

  Next, as shown in FIG. 4, the claw portions 22 a and 22 b of the connection terminal 21 are bent and abutted so as to be close to each other (inward), and the conductor 31 is fastened by the claw portions 22 a and 22 b and the flat portion 23.

  Next, the electrode 45 is brought into contact with the butted portion 42 in the claw portions 22 a and 22 b and the vicinity thereof, and the electrode 46 is brought into contact with the lower surface of the flat portion 23 of the connection terminal 21.

  Next, by applying a voltage between the electrodes 45, 46, the electrode 45 → the butted portion 42 of the connection terminal 21 → the conductor 31 → the flat portion 23 of the connection terminal 21 → the electrode 46 (in reverse order). Current flows. When this current flows, the conductor 31 and the layer 11 and the surfaces of the conductors 31 are partially thermally melted by the heat generated by the electrical resistance (Joule heat). As a result, at least a part of the conductor 31 and the layer 11 and at least a part of the conductors 31 are fused and integrated to form the fused part 38 (second fusion process). Here, when a voltage is applied by the electrodes 45 and 46, at least one of the electrodes 45 and 46 is moved in a direction close to each other, and the abutting portion 42, the conductor 31, and the flat portion 23 between the electrodes 45 and 46 are compressed. You may do it.

  Thus, the connection (fixation) between the conductor 31 and the connection terminal 21 is completed, and a connection portion is obtained.

  Also in the connection part obtained using the connection method according to the present embodiment, the same effects as those of the connection parts 30 and 40 obtained using the connection method according to the previous embodiment are expected. Moreover, the connection strength of the connection part which concerns on this Embodiment becomes still higher than the connection strength of the connection parts 30 and 40 which concern on previous embodiment.

  As described above, in the connection method according to the present embodiment, the case where the fused portion 38 is formed by applying ultrasonic vibration and / or applying voltage has been described. However, the method for forming the fused portion 38 is not particularly limited as long as at least a part of the conductor 31 and the layer 11 and at least a part of the conductors 31 can be fused and integrated.

  As described above, the present invention is not limited to the above-described embodiment, and it goes without saying that various other things are assumed.

  Next, although this invention is demonstrated based on an Example, this invention is not limited to this Example.

Example 1
An Al alloy plate and an Fe alloy plate are laminated and clad in two layers, and a composite material (see FIG. 1) in which the layer thickness ratio of the Al alloy layer and the Fe alloy layer is adjusted to 5: 1 is produced. Using this composite material, the connection terminal shown in FIG. 2 is produced.

  After the conductor is inserted and arranged in the space of the connection terminal, ultrasonic vibration is applied to the connection terminal and the conductor using the connection method described with reference to FIG. At this time, one ultrasonic transducer is moved in a direction close to the other ultrasonic transducer, and a compressive force is applied to the conductor and the flat portion between the ultrasonic transducers. In this way, a fusion part is formed in at least a part of the conductor and Al alloy layer, and at least a part of the conductors, and the connection part shown in FIG.

(Example 2)
After a conductor is inserted and arranged in the connection terminal space similar to that in the first embodiment, a current is passed through the connection terminal and the conductor located between the two electrodes using the connection method described with reference to FIG. At this time, one ultrasonic transducer is moved in a direction close to the other ultrasonic transducer, and a compressive force is applied to the conductor and the flat portion between the ultrasonic transducers. In this way, a fusion part is formed in at least a part of the conductor and Al alloy layer and at least a part of the conductors, and the connection part shown in FIG. 4 is produced.

(Conventional example 1)
The connection terminal shown in FIG. 6 is produced using an industrial pure Al plate.

  After the conductor is inserted and arranged in the space of the connection terminal, the claw portions of the connection terminal are bent so as to be close to each other (inward), thereby producing the connection portion shown in FIG.

(Conventional example 2)
The connecting portion shown in FIG. 7 is produced in the same manner as in Conventional Example 1 except that an international standard annealed copper plate is used.

About each connection part of Example 1, 2 and the prior art examples 1, 2, while measuring electrical conductivity (x10 ⁶ S / m) and tensile strength (MPa), thermal shock resistance, steel recyclability, and comprehensive evaluation Each evaluation of was performed. These measurement results and evaluation are shown in Table 1.

  As shown in FIG. 5, the thermal shock resistance was evaluated by the change in resistivity ratio when the thermal cycle was continuously applied. Specifically, the thermal cycle of leaving for 1 hour under each temperature condition of −40 ° C. and 120 ° C. is defined as one cycle, and thermal shock (heat Cycle) was applied continuously (0 to 250 times), and the resistivity ratio was measured.

  As for steel recyclability, “good” indicates that the recyclability is good, and “poor” indicates that the recyclability is not good (poor).

  In the comprehensive evaluation, in consideration of electrical conductivity, tensile strength, thermal shock resistance, and steel recyclability, a good one was evaluated as “good” and a poor one as “poor”.

As shown in Table 1, the electrical conductivity of each connection part in Examples 1 and 2 is 30.2 × 10 ⁶ S / m, and the electrical conductivity of the connection part in Conventional Example 1 made of pure Al (35.5 × 10 ⁶ Compared with S / m), the conductivity was about 15% lower. However, the tensile strength of each connection part in Examples 1 and 2 was as extremely high as 350 MPa, which was three times higher than the tensile strength (115 MPa) of the connection part in Conventional Example 1. That is, each connection part of Examples 1 and 2 was very high in strength and had almost the same electrical conductivity as compared with a connection part configured using a pure Al connection terminal. .

  Further, as shown in Table 1 and FIG. 5, the resistivity ratio at each connection part of Examples 1 and 2 (illustrated by a broken line 51 connected with a circle and a bent line 52 connected with a triangle in FIG. 5) Even when the number of cycles increased from 0 to 250, there was almost no change (increase). Further, the increment of the resistivity ratio in the range of 0 to 250 cycles of each connection part of Examples 1 and 2 is smaller than that of the connection part of Conventional Example 2, and each of Examples 1 and 2 The thermal shock resistance of the connection part was the best among the connection parts of Examples 1 and 2 and Conventional Examples 1 and 2.

  Furthermore, each connection part of Examples 1 and 2 is configured using a connection terminal made of a clad material of an Al alloy and an Fe alloy, and because it is free of a specific metal material, steel recyclability was good. .

  From the above, each connection part of Examples 1 and 2 has high tensile strength, relatively good electrical conductivity, good thermal shock resistance, and good steel recyclability, so the overall evaluation is also good. there were.

  The connection part of Conventional Example 1 had good steel recyclability. However, as shown in FIG. 5, the resistivity ratio (shown by a broken line 53 with a black square in FIG. 5) in the connection portion of Conventional Example 1 rapidly increases at an early stage from the start of thermal shock application. When the number of cycles was about 100, the resistivity ratio had already reached a little less than 8, and when the number of cycles was 250, the resistivity ratio had reached just over 8. That is, the connection part of Conventional Example 1 was not good in thermal shock resistance, and the overall evaluation was poor.

Moreover, the connection part of the prior art example 2 has an electrical conductivity of 58.0 × 10 ⁶ S / m and a tensile strength of 400 MPa, both of which exceed the electrical conductivity and tensile strength of each connection part of Examples 1 and 2. It was. Further, as shown in FIG. 5, the resistivity ratio (shown by the broken line 54 connecting the black circles in FIG. 5) in the connection portion of the conventional example 2 is almost the same even when the number of cycles increases to 0 to 250 times. It did not change (increase) and was excellent in thermal shock resistance. However, since the connection part of Conventional Example 2 is configured using connection terminals made of pure Cu, the steel recyclability is not good and the overall evaluation is poor.

It is a perspective view of the composite material which comprises a connection terminal. 1 is a perspective view of a connection terminal according to a preferred embodiment of the present invention. It is a cross-sectional schematic diagram for demonstrating the connection method of the connection terminal which concerns on suitable one embodiment of this invention. It is a cross-sectional schematic diagram for demonstrating the connection method of the connection terminal which concerns on other preferable one Embodiment of this invention. It is a figure which shows the relationship between the cycle number of thermal shock provision in the connection part of Examples 1, 2 and the prior art examples 1, 2, and resistivity ratio. It is a perspective view of the conventional connection terminal. It is sectional drawing of the connection part connected using the connection method of the conventional connection terminal.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Composite material 11 Al alloy layer 12 Fe alloy layer 21 Connection terminal 31 Conductor 38 Fusion part

Claims (2)

In a method of connecting a connection terminal having a claw portion for bending tightening to a conductor made of Al or Al alloy of a cable end, it is composed of a composite material obtained by laminating and cladding an Al alloy layer and an Fe alloy layer. The conductor is brought into contact with a connection terminal formed by placing the Al alloy layer in contact with the conductor, and ultrasonic vibration is applied to at least one of the conductor or the connection terminal before bending the claw portion. A first fusing step of fusing and fusing at least a part of the contact portion between the conductor and the Al alloy layer with frictional heat due to sliding friction; and bending the claw portion of the connection terminal to A second conductor is fastened, a current is passed between the conductor and the connection terminal, and at least a part of a contact portion between the conductor and the Al alloy layer is melted and fused by Joule heat due to electric resistance. Fusion Connection method for connecting terminals, characterized in that it comprises a Chakukotei. A connection part comprising a conductor and a connection terminal connected using the connection method according to claim 1 .

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